Failure Analysis Dec16

Failure Analysis

Failure Analysis Failures of equipment components and assemblies, or structures in industry can cause loss of life, unscheduled shutdowns, increased maintenance and repair costs, and damaging litigation disputes. To prevent future recurrence of the problem caused by the failures ,it is essential to carry out an investigation in each failure. The conducting of an  investigation for a failure is known as failure analysis.  Failure analysis is a process of collecting and analyzing data and it is carried out to determine the causes or factors that have led to the undesired loss of functionality or failures of equipment components and assemblies, or structures. It is a multilevel process that includes physical investigation. The normal scope of a failure analysis is to find the failure mechanism and the most probable cause of the failure. The term failure mechanism is normally described as the metallurgical, chemical, mechanical, or tribological process leading to a particular failure mode. Failures of the equipment components and assemblies, or structures occur as a result of some sort of a mistake causing a weak link in the chain of the continuous process of engineering, design, manufacturing, and operation. The cause of a failure can be any one or more of the following. Fault in design Defects in material Deficiencies during processing and manufacturing Defects in assembly or installation Off-design or unintended service conditions Deficiencies in maintenance (neglect and procedures etc.) Improper operation Major steps while conducting a failure analysis are given in Fig 1. Fig 1 Majors steps in failure analysis The main principle of a failure analysis is to preserve evidence and the necessary information from the subject part or assembly in the as-received condition and the same is captured before anything is done to alter its condition. Further during failure analysis...